Surgical instruments and methods of manufacturing surgical instruments for performing tonsillectomy, adenoidectomy, and other surgical procedures

ABSTRACT

A surgical instrument includes a housing, a shaft extending distally from the housing, an end effector assembly disposed at a distal end of the shaft, a knife slidably disposed within the shaft, a movable handle operably coupled to the housing, a trigger operably coupled to the housing, a drive assembly operably coupled between the movable handle and the end effector assembly such that movement of the movable handle manipulates the end effector assembly, and a linkage operably coupled between the trigger and the knife such that movement of the trigger deploys the knife. In an initial position of the movable handle, a portion of a drive housing of the drive assembly intersects a path of movement of the linkage to inhibit movement of the linkage, thereby inhibiting actuation of the trigger.

BACKGROUND Technical Field

The present disclosure relates to surgical instruments and methods and,more particularly, to surgical instrument and methods for performingtonsillectomy, adenoidectomy, and other surgical procedures.

Background of Related Art

The tonsils and adenoids are part of the lymphatic system and aregenerally located in the back of the throat. These parts of thelymphatic system are generally used for sampling bacteria and virusesentering the body and activating the immune system when warranted toproduce antibodies to fight oncoming infections. More particularly, thetonsils and adenoids break down the bacteria or virus and send pieces ofthe bacteria or virus to the immune system to produce antibodies forfighting off infections.

Inflammation of the tonsils and adenoids (e.g., tonsillitis) impedes theability of the tonsils and adenoids to destroy the bacteria resulting ina bacterial infection. In many instances, the bacteria remain even aftertreatment and serve as a reservoir for repeated infections (e.g.,tonsillitis or ear infections).

A tonsillectomy and/or adenoidectomy may be performed when infectionspersist and antibiotic treatments fail. Some individuals are also bornwith larger tonsils that are more prone to cause obstruction. Anadenoidectomy may also be required to remove adenoid tissue when earpain persists, or when nose breathing or function of the Eustachian tubeis impaired. Often times, tonsillectomy and adenoidectomy procedures areperformed at the same time.

SUMMARY

As used herein, the term “distal” refers to the portion that is beingdescribed which is further from a user, while the term “proximal” refersto the portion that is being described which is closer to a user.Further, to the extent consistent, any of the aspects described hereinmay be used in conjunction with any or all of the other aspectsdescribed herein.

A surgical instrument provided in accordance with aspects of the presentdisclosure includes a housing, a shaft extending distally from thehousing, an end effector assembly disposed at a distal end of the shaft,a knife slidably disposed within the shaft, a movable handle operablycoupled to the housing and movable relative thereto between an initialposition and a compressed position, a trigger operably coupled to thehousing and movable relative thereto between an un-actuated position andan actuated position, a drive assembly operably coupled between themovable handle and the end effector assembly such that movement of themovable handle from the initial position to the compressed positionmoves the drive assembly to thereby manipulate the end effectorassembly, and a linkage operably coupled between the trigger and theknife such that movement of the trigger from the un-actuated position tothe actuated position moves the linkage to thereby deploy the kniferelative to the end effector assembly. The drive assembly includes adrive housing and the linkage defines a path of movement. In the initialposition of the movable handle, a portion of the drive housingintersects the path of movement to inhibit movement of the linkage todeploy the knife, thereby inhibiting movement of the trigger from theun-actuated position to the actuated position.

In an aspect of the present disclosure, movement of the trigger from theun-actuated position to the actuated position urges the linkage torotate to thereby deploy the knife.

In another aspect of the present disclosure, the linkage includes aprotruding lockout peg. In such aspects, in the initial position of themovable handle, the drive housing intersects a path of movement of thelockout peg.

In another aspect of the present disclosure, the drive housing istranslated proximally relative to the linkage upon movement of themovable handle from the initial position to the compressed position suchthat the drive housing is proximally displayed relative to the path ofmovement.

In yet another aspect of the present disclosure, the movable handle andthe trigger are pivotably coupled to the housing. In such aspects, themovable handle and the trigger may be pivotably coupled to the housingabout a common pivot.

In still another aspect of the present disclosure, the end effectorassembly includes first and second jaw members at least one of which ismovable relative to the other from a spaced-apart position to anapproximated position upon movement of the movable handle from theinitial position to the compressed position.

In still yet another aspect of the present disclosure, the drive housingat least partially houses a spring configured to limit a pressureapplied by the first and second jaw members. The spring may be a torsionspring.

In another aspect of the present disclosure, the trigger at leastpartially surrounds the movable handle. Additionally or alternatively,the trigger and the movable handle may define complementarily-contouredabutting surfaces.

Also provided in accordance with aspects of the present disclosure is ajaw member configured for use with a surgical instrument. The jaw memberincludes an electrically-conductive plate defining a planartissue-contacting surface and a pair of legs extending from the planartissue-contacting surface. The legs define outwardly-facing surfaces andinwardly-facing surfaces. The jaw member further includes a spacerincluding a body positioned towards a proximal portion of theelectrically-conductive plate, and a pair of arms extending distallyfrom the body adjacent the inwardly-facing surfaces to providestructural support to the electrically-conductive plate. A jaw framesupports the spacer and the electrically-conductive plate, and an outerhousing is disposed about at least a portion of the outwardly-facingsurfaces of the legs of the electrically-conductive plate, the spacer,and the jaw frame.

In an aspect of the present disclosure, the spacer further includes apair of wings extending outwardly from the body. The wings areconfigured to receive free ends of the legs of theelectrically-conductive plate to engage the spacer with theelectrically-conductive plate.

In another aspect of the present disclosure, the legs of theelectrically-conductive plate each define a plurality of aperturestherethrough. In such aspects, the arms of the spacer may defineprotrusions extending outwardly therefrom, each extending at leastpartially through one of the plurality of apertures. Additionally oralternatively, a portion of the outer housing may extend at leastpartially through one of the plurality of apertures of each of the legsof the electrically-conductive plate.

In still another aspect of the present disclosure, the spacer furtherdefines a tunnel configured to receive a lead wire for connecting theelectrically-conductive plate to a source of energy.

In yet another aspect of the present disclosure, the jaw frame includesa distal support portion that extends from about 50% to about 75% of thelength of the electrically-conductive plate.

In still yet another aspect of the present disclosure, the jaw frameincludes a proximal flange portion extending proximally from the distalsupport portion. The proximal flange portion defines at least one pivotaperture and at least one cam slot.

In another aspect of the present disclosure, the legs of theelectrically-conductive plate extend perpendicularly from the planartissue-contacting surface.

BRIEF DESCRIPTION OF THE DRAWINGS

Various aspects and features of the present disclosure described hereinwith reference to the drawings wherein:

FIG. 1 is a perspective view of a surgical instrument provided inaccordance with the present disclosure with jaw members of the endeffector assembly of the surgical instrument disposed in a spaced-apartposition;

FIG. 2 is a rear, perspective view of the surgical instrument of FIG. 1with the jaw members disposed in the approximated position and a portionof the housing removed to illustrate the internal components thereof;

FIG. 3 is a front, perspective, partially-exploded view of the surgicalinstrument of FIG. 1 with the jaw members disposed in the approximatedposition and a portion of the housing removed to illustrate the internalcomponents thereof;

FIG. 4 is an enlarged, perspective view of the linkage of the triggerassembly of the surgical instrument of FIG. 1;

FIG. 5 is a rear, perspective view of the handle, trigger, and driveassemblies of the surgical instrument of FIG. 1 with a movable handle ofthe handle assembly disposed in a partially-actuated position and atrigger of the trigger assembly disposed in an un-actuated position;

FIG. 6 is a front, perspective view of the drive assembly, shaft, andend effector assembly of the surgical instrument of FIG. 1;

FIG. 7 is an enlarged, perspective view of the area of detail indicatedas “7” in FIG. 6;

FIG. 8 is another enlarged, perspective view of the proximal end of thedrive assembly of the surgical instrument of FIG. 1;

FIG. 9 is a longitudinal, cross-sectional view taken along section line“9-9” of FIG. 8;

FIG. 10 is a rear, perspective, exploded view of the drive assembly,shaft, knife, and end effector assembly of the surgical instrument ofFIG. 1;

FIG. 11 is an enlarged, perspective view of the area of detail indicatedas “11” in FIG. 10;

FIG. 12 is another enlarged, perspective view of the distal end of theknife blade of the surgical instrument of FIG. 1;

FIG. 12′ is an enlarged, perspective view of the distal end of anotherknife blade configured for use with the surgical instrument of FIG. 1 orany other suitable surgical instrument;

FIG. 13 is a perspective view of the distal end of the surgicalinstrument of FIG. 1 with the jaw members disposed in the spaced-apartposition;

FIG. 14 is another perspective view of the distal end of the surgicalinstrument of FIG. 1 with the jaw members disposed in the spaced-apartposition;

FIG. 15 is a side, perspective view of one of the jaw members of thesurgical instrument of FIG. 1 with a portion thereof removed;

FIG. 16 is a transverse, cross-sectional view of the jaw member of FIG.15;

FIG. 17 is a perspective view of the electrically-conductive plate ofone of the jaw members of the surgical instrument of FIG. 1;

FIG. 18 is a top view of the electrically-conductive plate of one of thejaw members of the surgical instrument of FIG. 1 including an overmoldedspacer disposed thereon;

FIG. 19 is a perspective view of the electrically-conductive plate, jawframe, and overmolded spacer of one of the jaw members of the surgicalinstrument of FIG. 1;

FIG. 20 is a longitudinal, cross-sectional view of the surgicalinstrument of FIG. 1 with the surgical instrument disposed in an initialposition;

FIG. 21 is an enlarged, side, cross-sectional view of the area of detailindicated as “21” in FIG. 20;

FIG. 22 is a perspective view of the surgical instrument of FIG. 1 withthe movable handle disposed in a compressed position and, accordingly,the jaw members disposed in the approximated position;

FIG. 23 is an enlarged, perspective view of the area of detail indicatedas “23” in FIG. 22;

FIG. 24 is an enlarged, longitudinal, cross-sectional view of theinternal components of the housing of the surgical instrument of FIG. 1,wherein the movable handle is disposed in the compressed position;

FIG. 25 is a perspective view of the distal end of the drive, knife, andend effector assemblies of the surgical instrument of FIG. 1, with thejaw members disposed in the spaced-apart position;

FIG. 26 is a perspective view of the distal end of the drive, knife, andend effector assemblies of the surgical instrument of FIG. 1, with thejaw members disposed in the approximated position;

FIG. 27 is a perspective view of the proximal end of the surgicalinstrument of FIG. 1 with the movable handle disposed in an activatedposition and a portion of the housing removed to illustrate the internalcomponents thereof;

FIG. 28 is a perspective view of the proximal end of the surgicalinstrument of FIG. 1 with the trigger disposed in an actuated positionand a portion of the housing removed to illustrate the internalcomponents thereof;

FIG. 29 is a perspective view of the distal end of the drive and knifeassemblies of the surgical instrument of FIG. 1 with the knife assemblydisposed in an extended position; and

FIG. 30 is a perspective view of the distal end of the drive and knifeassemblies as shown in FIG. 29 and further including the jaw membersdisposed in the approximated position.

DETAILED DESCRIPTION

Referring generally to FIG. 1, a surgical instrument provided inaccordance with the present disclosure is shown generally identified byreference numeral 10. Instrument 10, as described below, is configuredfor grasping, treating, and/or dissecting tissue and may find particularapplicability for use in performing tonsillectomy procedures and/oradenoidectomy procedures, although use of instrument 10 in various othersurgical procedures is also contemplated and within the scope of thepresent disclosure. Additional features contemplated for use withinstrument 10 are detailed in commonly-owned U.S. patent applicationSer. Nos. 14/719,422, 14/719,434, 14/719,452, 14/719,464, and14/719,475, each of which was filed on May 22, 2015, and is incorporatedherein by reference in its entirety.

With reference to FIGS. 1-3, 5, and 10, instrument 10 generally includesa housing 20, a handle assembly 30, a trigger assembly 70, a shaft 80,an end effector assembly 100, a drive assembly 140, a knife assembly170, and an energy activation assembly 190. As detailed below, shaft 80extends distally from housing 20 and supports end effector assembly 100at distal end of shaft 80, drive assembly 140 operably couples handleassembly 30 with end effector assembly 100 to enable selectivemanipulation of jaw members 110, 120 of end effector assembly 100, knifeassembly 170 is operably coupled with trigger assembly 70 to enableselective translation of a knife blade 174 (FIGS. 11 and 12) of knifeassembly 170 relative to end effector assembly 100, and energyactivation assembly 190 enables energy to be selectively delivered toend effector assembly 100.

Instrument 10 also includes an electrosurgical cable 200 including aproximal plug 210 that connects instrument 10 to a generator (not shown)or other suitable power source, although instrument 10 may alternativelybe configured as a battery-powered instrument. Electrosurgical cable 200includes lead wires, e.g., lead wires 107 (FIG. 10), extendingtherethrough that have sufficient length to extend through housing 20and shaft 80 in order to operably couple the generator, energyactivation assembly 190, and end effector assembly 100 with one anotherto enable the selective supply of energy to electrically-conductiveplates 112, 122 of jaw members 110, 120 of end effector assembly 100,e.g., upon activation of activation switch 194 of energy activationassembly 190.

Referring to FIGS. 1-3, housing 20 houses the internal workingcomponents of instrument 10 and is formed from first and second housingcomponents configured to engage one another via a plurality ofpin-aperture engagements spaced around housing 20, although othersuitable engagements, e.g., screws, snap-fit connections, adhesion,ultrasonic welding, etc., are also contemplated, as are differentformations of housing 20. Housing 20 defines a pistol-styleconfiguration having a longitudinally-extending barrel portion 22 and afixed handle portion 28 that extends from barrel portion 22 in generallyperpendicular orientation relative thereto.

Barrel portion 22 of housing 20 defines a distal aperture configured toreceive and engage the proximal end of shaft 80 therein. Shaft 80extends distally from barrel portion 22 of housing 20 and defines agenerally rectangular cross-sectional configuration oriented such thatthe larger width dimension thereof extends laterally and the smallerheight dimension thereof extends vertically. This configuration of shaft80 relative to the orientation of jaw members 110, 120 provides enhanced“line-of-sight” for visualizing the surgical site adjacent end effectorassembly 100. As described in greater detail below, shaft 80 includes apair of spaced-apart clevis members 84 extending from the top and bottomwalls, e.g., the larger width dimension walls, of shaft 80 at the distalend of shaft 80. Each clevis member 84 defines an aperture 86 forreceiving a pivot pin 103 to operably support end effector assembly 100at the distal end of shaft 80.

Barrel portion 22 of housing further includes a pair of opposed pivotapertures 23 (only one of which is shown), a longitudinal track 24, apair of opposed pivot bosses 25 (only one of which is shown), and ablock 26. Each pivot aperture 23 is configured to receive an end ofpivot pin 48 to pivotably couple movable handle 40 and trigger 72 tohousing 20. Alternatively, a separate pivot pin 48′ received betweenseparate pivot apertures 23′ (only one of which is shown) may beprovided for coupling movable handle 40 to housing 20 such that movablehandle 40 and trigger 72 are not coupled about the same pivot pin 48but, rather, are coupled about spaced-apart pivot pins 48′, 48,respectively. Further still, movable handle 40 and trigger 72 may bepivotably coupled about the same pivot pin, pivot pin 48′, at thelocation of pivot apertures 23′ rather than pivot apertures 23.Longitudinal track 24 is configured to guide translation of driveassembly 140 relative to housing 20. Pivot bosses 25 extend inwardlyinto housing 20 and are configured to pivotably couple linkage 76 oftrigger assembly 70 to housing 20. Lower leg 163 of torsion spring 160of drive assembly 140 is configured to abut block 26 under bias to biasmovable handle 40 towards the initial position, as detailed below.

Energy activation assembly 190 includes a depressible button 192 that ismechanically coupled to a switch 194 mounted within a bay 29 definedwithin fixed handle portion 28 of housing 20 and is engagable by abutton activation post 196 extending proximally from a proximal side ofmovable handle 40 upon movement of movable handle 40 to the activatedposition, as detailed below. Switch 194 is configured to electricallycommunicate with end effector assembly 100 and the generator (not shown)via suitable electrical wiring, e.g., leads 107 (FIG. 10), extendingthrough housing 20, shaft 80, and/or electrosurgical cable 200 to enableenergy to be supplied from the generator (not shown) to end effectorassembly 100 upon activation of switch 194.

Continuing with reference to FIGS. 1-3, handle assembly 30 includes amovable handle 40 that is movable relative to fixed handle portion 28 ofhousing 20 between an initial position, a compressed position, and anactivated position, as explained in greater detail below, to impartmovement of jaw members 110, 120 of end effector assembly 100 between aspaced-apart position and an approximated position for grasping tissuetherebetween and for initiating the supply of energy to end effectorassembly 100 for treating grasped tissue. Movable handle 40 and trigger72 of trigger assembly 70 are ergonomically configured to facilitatemanipulation and operation of instrument 10. Movable handle 40, morespecifically, defines a grasping portion 42 having an arcuate segment 43and an elongated proximal leg 44 that extends from arcuate segment 43the length of fixed handle portion 28 of housing 20. Arcuate segment 43culminates in a distal tail 45 and defines a sufficient diameter so asto operably receive a user's finger between distal tail 45 and proximalleg 44. Arcuate segment 43 further defines a convex surface 46. Trigger72, more specifically, defines an abutting surface 73 that abuts convexsurface 46 of arcuate segment 43 of movable handle 40 and iscomplementarily contoured such that, in the initial position of movablehandle 40 and the un-actuated position of trigger 72, pinch pointsbetween trigger 72 and movable handle 40 are eliminated. Further,trigger 72 surrounds the exposed part of flange portion 47 of movablehandle 40 to eliminate pinch points therebetween.

Movable handle 40, as noted above, includes grasping portion 42, whichextends from housing 20 adjacent fixed handle portion 28, and flangeportion 47, which extends upwardly into housing 20. Flange portion 47 ispivotably coupled within housing 20 at the free end of flange portion 47via pivot pin 48. Pivot pin 48 is engaged within and extends betweenpivot apertures 23 of housing 20 to permit movable handle 40 to pivotabout pivot pin 48 and relative to housing 20 between the initialposition (FIGS. 1 and 2), the compressed position (FIG. 22), and theactivated position (FIG. 27). Flange portion 47 of movable handle 40further includes a cut-out 49 defined therein and an engagement bulge 51protruding therefrom. Cut-out 49 is configured to slidably receive driveplate 142 of drive assembly 140 and knife plate 172 of knife assembly170. Engagement bulge 51 is configured to operably engage flange portion47 of movable handle 40 with slider assembly 150 of drive assembly 140,as detailed below.

Referring to FIGS. 5-10, drive assembly 140 includes drive plate 142 andslider assembly 150. Drive plate 142 extends distally from housing 20and through shaft 80 to operably engage end effector assembly 100 suchthat, as detailed below, translation of drive plate 142 through shaft 80and relative to end effector assembly 100 pivots jaw members 110, 120 ofend effector assembly 100 between the spaced-apart and approximatedpositions.

Slider assembly 150 operably couples engagement bulge 51 of flangeportion 47 of movable handle 40 with drive plate 142 such that pivotingof movable handle 40 between the initial position and the compressedposition pivots jaw members 110, 120 of end effector assembly 100between the spaced-apart and approximated positions, while ensuringapplication of an appropriate closure force or closure force within anappropriate closure force range to tissue grasped between jaw members110, 120 in the approximated position thereof.

Slider assembly 150 includes a proximal housing 152, a distal extension156 extending distally from proximal housing 152, a mandrel 158 disposedat the distal end of distal extension 156, and a torsion spring 160operably coupled to proximal housing 152. Proximal housing 152 includesa post 153 configured to receive body 161 of torsion spring 160thereabout and open upper and lower portions configured to permitpassage of the upper and lower legs 162, 163, respectively, of torsionspring 160 therethrough. Lower leg 163 extends downwardly from proximalhousing 152 and is positioned to abut block 26 (which may be configuredas a half-moon boss) of housing 20, thereby biasing slider assembly 150distally and, thus, movable handle 40 towards the initial position.Torsion spring 160 remains tensioned in the initial position of movablehandle 40 such that a pre-load on drive assembly 140 is maintained.Proximal housing 152 further includes an abutment rib 154 disposed on anupper surface thereof, and a longitudinal flange 155 slidably receivedwithin longitudinal track 24 of housing 20.

Continuing with reference to FIGS. 5-10, mandrel 158 is disposed at thedistal end of distal extension 156 and defines a channel 159 configuredto receive engagement bulge 51 of flange portion 47 of movable handle40. As a result of this configuration, upon pivoting of movable handle40 between the initial, compressed, and activated positions, engagementbulge 51 is urged into contact with one of the walls of mandrel 156 tothereby translate slider assembly 150 within housing 20.

Drive plate 142 includes a flange 143 and a slot 144 towards theproximal end thereof and a cam pin aperture 147 and a mouth 149 towardsthe distal end thereof. Slot 144 is configured to receive upper leg 162of torsion spring 160 therethrough such that translation of upper leg162 of torsion spring 160 relative to housing 20 effects translation ofdrive plate 142 relative to housing 20. Flange 143 is slidably disposedon an upper surface of proximal housing 152 and defines a proximal edge145 configured to abut abutment rib 154 of proximal housing 152 in aproximal-most position of drive plate 142 relative to slider assembly150 to inhibit further proximal movement of drive plate 142 relative toslider assembly 150.

Drive plate 142 extends distally from housing 20 and through shaft 80 tooperably engage end effector assembly 100. Drive plate 142 is orientedsimilarly to shaft 80, such that the width of drive plate 142 extendsalong the width dimension of shaft 80. Drive plate 142 further defines atrack edge 146 extending along a portion of each longitudinal sidethereof. Track edges 146 are configured to slidably receive knife plate172. A knife guide 148 is pinned to drive plate 142 towards the distalend thereof to define a channel configured to slidably receive and guidetranslation of knife blade 174. Knife guide 148 also provides furtherstability to cam pin 105. Cam-pin aperture 147 is configured to receivecam pin 105 of end effector assembly 100, while mouth 149 is configuredto receive pivot pin 103 of end effector assembly 100.

Referring to FIGS. 2-12, trigger assembly 70, as mentioned above, isoperably coupled to knife assembly 170 to enable selective translationof knife blade 174 of knife assembly 170 relative to end effectorassembly 100. Trigger assembly 70 includes trigger 72 and a linkage 76.Trigger 72, as detailed above, includes an abutting surface 73 definedon a grasping portion 74 thereof. Trigger 72 further includes a pivotextension 75 a extending upwardly from grasping portion 74 and aproximal extension 75 b extending proximally from grasping portion 74.Pivot extension 75 a of trigger 72 is pivotably coupled to housing 20via pivot pin 48. Proximal extension 75 b of trigger 72 includes a post75 c that is received within lower end cam slot 77 c of linkage 76 tooperably couple trigger 72 to linkage 76. A biasing member 71 is coupledbetween housing 20 and trigger 72 to bias trigger 72 distally towards anun-actuated position (FIG. 2).

Linkage 76 serves to operably couple trigger 72 with knife assembly 170such that pivoting of trigger 72 from the un-actuated position to theactuated position advances knife blade 174 (FIGS. 10-12) between jawmembers 110, 120 of end effector assembly 100 to cut tissue graspedtherebetween. Linkage 76 includes an apex 77 a pointing in a distaldirection and upper and lower end cam slots 77 b, 77 c, respectively.Apex 77 a includes a peg 77 d that is configured for receipt withinpivot boss 25 of housing 20 to pivotably couple linkage 76 relative tohousing 20 about apex 77 a. A coupling tube 78 engaged with knife plate172 of knife assembly 170 is configured for receipt within upper end camslot 77 b to operably couple linkage 76 to knife plate 172. Morespecifically, coupling tube 78 is configured to receive legs 173, whichextend transversely from the proximal end of knife plate 172, insnap-fit engagement therein (see FIG. 9). As noted above, post 75 c ofproximal extension 75 b of trigger 72 is configured for receipt withinlower end cam slot 77 c of linkage 76.

As a result of the above-detailed configuration, Pivoting of trigger 72between the un-actuated and actuated positions urges linkage 76 to pivotrelative to housing 20 such that coupling tube 78 is urged to translatelongitudinally within and relative to housing 20. As legs 173 of knifeplate 172 are engaged with coupling tube 78, such longitudinaltranslation of coupling tube 78 is imparted to knife plate 172 fortranslating knife blade 174 (FIGS. 10-12) from a retracted position toan extended position relative to jaw members 110, 120 of end effectorassembly 100.

Linkage 76 of trigger assembly 70 further includes a lockout peg 79extending transversely from linkage 76 and positioned between apex 77 aand lower end cam slot 77 c. In the initial position of movable handle40, proximal housing 152 of slider assembly 150 is disposed in a moredistal position so as to interfere with the movement path of lockout peg79 (see FIG. 21), thus inhibiting actuation of trigger 72 when movablehandle 40 is disposed in its initial position. Upon movement of movablehandle 40 sufficiently towards the compressed position, proximal housing152 of slider assembly 150 is moved proximally out of the movement pathof lockout peg 79 (see FIG. 24), permitting rotation of linkage 76 and,thus, actuation of trigger 72.

With reference to FIGS. 8-12, knife assembly 170, as noted above,includes a knife plate 172 defining legs 173 extending transverselytherefrom towards the proximal end thereof. Knife plate 172 extendsdistally through housing 20 and shaft 80 atop drive plate 142 and isslidably engaged therewith via receipt of each side of knife plate 172within track edges 146 of drive plate 142. Knife assembly 170 furtherincludes knife blade 174 integrally formed with or otherwise engaged toknife plate 172 and extending distally therefrom. Knife blade 174 isslidably disposed within the channel defined between drive plate 142 andknife guide 148 and defines a serrated distal cutting edge 175 (seeFIGS. 11 and 12) to facilitate cutting tissue grasped between jawmembers 110, 120 of end effector assembly 100. Knife blade 174 furtherdefines an elongated opening 176 extending longitudinally therethrough.Elongated opening 176 permits knife blade 174 to be slidably disposedabout pivot pin 103 and cam pin 105. More specifically, elongatedopening 176 defines a first portion 177 a, a second portion 177 b, and athird portion 177 c (FIG. 10). First portion 177 a has a first widthconfigured to slidably receive pivot pin 103 and cam pin 105. Secondportion 177 b extends distally from first portion 177 a, has a secondwidth, and is configured to facilitate compliance of knife blade 174 asit is translated through the curved end effector assembly 100 (FIG. 13).Third portion 177 c (FIG. 10) extends proximally from first portion 177a and has a third width (equal to or different from the second width)configured to slidably receive cam pin 105 but sufficiently small toinhibit receipt of the larger-diameter pivot pin 103 therein.

Turning to FIG. 12′, another knife blade 174′ configured for use withinstrument 10 is provided. To the extent consistent, and unlesscontradicted hereinbelow, knife blade 174′ may include similar features,functions, and connections to the other components of instrument 10 asthose detailed herein with respect to knife blade 174 (FIGS. 11 and 12).Knife blade 174′ defines a heightened distal portion 174 a′ and arelatively shorter body portion 174 b′. The heightened distal portion174 a′ of knife blade 174′ inhibits tissue from being positioned aboveor below knife blade 174′ as knife blade 174′ is translating through endeffector assembly 100 (FIG. 14), while the shorter body portion 174 b′of knife blade 174′ maintains a low profile configuration within shaft80 (FIG. 14). Knife blade 174′ further defines an elongated opening 177′therethrough that, although shown as having a generally constant width,may alternatively be configured similar to elongated opening 176 ofknife blade 174 (FIGS. 11 and 12).

The distal cutting edge 175′ of knife blade 174′ defines a dual rakeconfiguration, wherein the edge portions of distal cutting edge 175′extend distally and angle inwardly towards one another, ultimatelyculminating in a point that is generally centered about a longitudinalaxis of knife blade 174′ and positioned distally of heightened distalportion 174 a′ of knife blade 174′. This configuration of distal cuttingedge 175′ has been found to: reduce the force required to advance knifeblade 174′ through tissue due to its aerodynamic configuration; enablecutting further towards the distal tip of end effector assembly 100(FIG. 14) by virtue of the inwardly and distally extending cutting edgeportions of distal cutting edge 175′; and enable a reduction in overalljaw height for either or both of the jaw members 110, 120 withoutrestricting knife performance.

With reference to FIGS. 10 and 13-19, as mentioned above, end effectorassembly 100 is operably supported at the distal end of shaft 80 andincludes opposing jaw members 110, 120 pivotably coupled to one anotherand movable relative to one another and shaft 80 between a spaced-apartposition and an approximated position for grasping tissue therebetween.Jaw members 110, 120 are similar to one another, unless otherwisedetailed hereinbelow. Thus, common features to both jaw member 110 andjaw member 120 may not be described and/or illustrated with respect toeach of jaw members 110, 120.

Each jaw member 110, 120 includes an electrically-conductive plate 132,a jaw frame 134, a spacer 136, and an outer housing 138, each of whichis detailed below. Jaw members 110, 120 define curved configurations,wherein jaw members 110, 120 bend upwardly from a longitudinal axis ofshaft 80, e.g., towards the upper, larger width dimension wall of shaft80. This configuration facilitates use of instrument 10 in tonsillectomyand adenoidectomy procedures as well as other surgical procedures andallows for increased visualization of the surgical site in these andother procedures.

The electrically-conductive plate 132 of each jaw member 110, 120defines a generally planar tissue-contacting surface 132 a, an elongatedknife slot 132 b extending through the respective tissue-contactingsurface 132 a, a pair of legs 132 c extending downwardly from each sideof the respective tissue-contacting surface 132 a, and a distal edge 132d disposed at the distal end of the respective tissue-contacting surface132 a.

The tissue-contacting surface 132 a of jaw member 110 and/or jaw member120 may include a plurality of stop members 132 e disposed thereon. Stopmembers 132 e may be constructed of a heat-resistant ceramic, anon-conductive plastic, an electrically conductive material isolatedfrom the respective tissue-contacting surface 132 a, or any othersuitable material, and/or may be deposited, molded, inserted throughapertures, or otherwise formed on the tissue-contacting surface 132 a ofjaw member 110 and/or jaw member 120. Legs 132 c ofelectrically-conductive plates 132 each define a plurality of apertures132 f therethrough.

Jaw frames 134 of jaw members 110, 120 each include a pair ofspaced-apart proximal flanges 134 a and a distal jaw support 134 bextending distally from the proximal flanges 134 a. Proximal flanges 134a of jaw member 110 are spaced-apart further than proximal flanges 134 aof jaw member 120 so as to allow proximal flanges 134 a of jaw member120 to be positioned between proximal flanges 134 a of jaw member 110during assembly. Further, the proximal flanges 134 a of each pair definealigned pivot apertures 134 c and aligned cam slots 134 d. Pivot pin 103of end effector assembly 100 is configured for vertical insertionthrough apertures 86 of clevis members 84 of shaft 80 and pivotapertures 13 c to pivotably couple jaw members 110, 120 to shaft 80 andone another. Pivot pin 103 is further configured to at least partiallyenter mouth 149 of drive plate 142 to permit drive plate 142 to slidefurther distally relative to end effector assembly 100 to a positionwherein mouth 149 of drive plate 142 at least partially surrounds pivotpin 103.

Continuing with reference to FIGS. 10 and 13-19, the cam slots 134 d ofproximal flanges 134 a of jaw member 110 are oppositely angled relativeto the cam slots 134 d of proximal flanges 134 a of jaw member 120. Campin 105 of end effector assembly 100 is configured for insertion througheach cam slot 134 d as well as cam-pin aperture 147 of drive plate 142to operable couple drive plate 142 with jaw members 110, 120 such thattranslation of drive plate 142 relative to jaw members 110, 120 pivotsjaw members 110, 120 about pivot pin 103 and relative to one another andshaft 80 between the spaced-apart and approximated positions.

Distal jaw supports 134 b of jaw frames 134 of jaw members 110, 120define generally “L-shaped” configurations and are configured to supportelectrically-conductive plates 132, spacers 136, and outer housings 138of jaw members 110, 120. However, distal jaw supports 134 b only extenda length of about 50% to about 75% of the length of jaw members 110,120.

Spacers 136 of jaw members 110, 120 define generally “M-shaped”configurations, are formed from electrically-insulative materials, andare overmolded onto distal jaw supports 134 b during a first overmold,although other manufacturing processes are also contemplated. Spacers136 are positioned to electrically-isolate electrically-conductiveplates 132 from one another and from jaw frames 134. Spacers 136 eachdefine a body 136 a, a pair of wings 136 b surrounding body 136 a, and apair of support arms 136 c extending distally from the correspondingbody 136 a. The bodies 136 a of spacers 136 define tunnels 136 e forpassage of lead wires 107 therethrough to electrically coupleelectrically-conductive plates 132 to switch 194 of energy activationassembly 190 (FIGS. 1 and 2) and the generator (not shown). Wings 136 bcapture the legs 132 c of electrically-conductive plates 132.

Support arms 136 c of spacers 136 b extend along the legs 132 c ofelectrically-conductive plate 132 to provide structural support thereto,and may define equal or different lengths. For example, due to thecurved configuration of jaw members 110, 120, additional supportadjacent the interior or concave side may be required and, thus, thesupport arm 136 c adjacent thereto may be longer than the support arm136 c adjacent the outer or convex side. However, other configurationsare also contemplated. Support arms 136 c further include protrusions136 d that extend therefrom through some but not all of the apertures132 f defined along the length of legs 132 c of electrically-conductiveplates 132 to secure support arms 136 c thereto and reinforce thestructural stability thereof. The above-detailed configuration ofsupport arms 136 c inhibits legs 132 c of electrically-conductive plates132 from bending, buckling, and/or becoming wave-shaped under the forcesapplied thereto during overmolding, assembly, and/or use.

Outer housings 138 are formed about jaw members 110, 120 via a secondovermold process, such that each outer housing 138 partially enclosesrespective jaw members 110, 120 with the exception of a portion of thedistal jaw support 113 b, 123 b thereof and the tissue-contactingsurface 112 a, 122 a thereof, which remain exposed. Further, theapertures 132 f defined through legs 132 c of electrically-conductiveplates 132 that are not occupied by protrusions 136 d of arms 136 c ofspacers 136 are filled via portions of outer housing 138 during thesecond overmold process to ensure that electrically-conductive plates132 are secured in position. Outer housings 138 also define windows 139that align with and communicate with the knife slots 132 b ofelectrically-conductive plates 132 so as to define an opening throughthe distal portions of jaw members 110, 120 transversely from thetissue-contacting surfaces 132 a of electrically-conductive plates 132to the outer surfaces of outer housings 138.

With outer housings 138 formed about jaw members 110, 120, respectively,distal edges 132 d of electrically-conductive plates 132 overlap thedistal ends of outer housings 138 such that distal edges 132 d can beutilized to pinch tissue therebetween. Further, outer housings 138 eachdefine cut-outs on the outer surfaces thereof towards the distal endsthereof that form shelves 109 on the outer surfaces of jaw members 110,120 to facilitate poking and spreading tissue.

Turning now to FIGS. 20-30, the use and operation of instrument 10 isdescribed. Initially, as illustrated in FIGS. 20, 21, and 25, movablehandle 40 is biased towards the initial position by the abutment oflower leg 163 of torsion spring 160 with block 26 of housing 20. Withmovable handle 40 in the initial position, slider assembly 150 islikewise disposed in a distal-most position. With slider assembly 150disposed in its distal-most position, upper leg 162 of torsion spring160 retains drive plate 142 in a distal-most position with the proximaledge 145 of drive plate 142 disposed in abutment with abutment rib 154of proximal housing 152 of slider assembly 150. In the distal-mostposition of drive plate 142, drive plate 142 and knife guide 148maintain cam pin 105 at the distal ends of oppositely-angled cam slots134 d of proximal flanges 134 a of jaw members 110, 120 to therebymaintain jaw members 110, 120 in the spaced-apart position (see FIG.25).

At this point, with continued reference to FIGS. 20, 21, and 25, trigger72 is disposed in the un-actuated position, wherein trigger 72 is in adistal-most position under the bias of biasing member 71 such that upperend cam slot 77 b of linkage 76 is disposed in a proximal-most positionwhile lower end cam slot 77 c of linkage 76 is disposed in a distal-mostposition. Thus, knife plate 172 is disposed in a proximal-most position,corresponding to a retracted position of knife blade 174, wherein knifeblade 174 is disposed between proximal flanges 134 a of jaw frames 134of jaw members 110, 120 but does not extend distally therefrom. Further,with movable handle 40 disposed in its initial position, proximalhousing 152 of slider assembly 150 is disposed in the movement path oflockout peg 79 of linkage 76, inhibiting rotation of linkage 76 and,thus, inhibiting movement of trigger 72 from the un-actuated position tothe actuated position. As such, knife blade 174 is inhibited from beingdeployed when jaw members 110, 120 are disposed in the spaced-apartposition.

With additional reference to FIGS. 22-24, and 26, in order to move jawmembers 110, 120 to the approximated position to grasp tissuetherebetween, movable handle 40 is pulled proximally towards fixedhandle portion 28 of housing 20 from the initial position to thecompressed position (FIGS. 22 and 24). Upon movement of movable handle40 to the compressed position, movable handle 40 urges slider assembly150 proximally through housing 20. Torsion spring 160, in an initial,less-tensioned state, is translated proximally together with sliderassembly 150 such that upper leg 162 of torsion spring 160 pulls driveplate 142 proximally in connection with the proximal translation ofslider assembly 150. In other words, at this point, slider assembly 150and drive plate 142 move in concert with one another. As drive plate 142is pulled proximally, cam pin 105 is pulled proximally through cam slots134 d of proximal flanges 134 a of jaw members 110, 120 such that jawmembers 110, 120 are pivoted from the spaced-apart position to theapproximated position (FIGS. 23 and 26) to grasp tissue therebetween.

Referring also to FIG. 27, in order to apply energy to tissue graspedbetween jaw members 110, 120 to treat tissue, movable handle 40 iscompressed further towards fixed handle portion 28 of housing 20 to anactivation position, wherein an appropriate closure force or closureforce within an appropriate range, is achieved and energy activation isinitiated. As movable handle 40 is moved further proximally relative tohousing 20 beyond the compressed position, an appropriate closure forceor closure force within an appropriate range is imparted to tissuegrasped between jaw members 110, 120 regardless of the thickness orcompressibility of tissue or the position of movable handle 40. This isbecause, upon movement of movable handle 40 from the compressed positiontowards the activation position, proximal housing 152 of slider assembly150 is translated proximally while drive plate 142 is maintained inposition. In other words, upon movement of movable handle 40 from thecompressed position to the activated position, proximal housing 152 anddrive plate 142 no longer move in concert with one another but aredecoupled to permit relative motion therebetween.

The decoupling of proximal housing 152 of slider assembly 150 and driveplate 142 to permit relative motion therebetween is provided via torsionspring 160. More specifically, upon proximal movement of movable handle40, a first force is imparted from movable handle 40, through proximalhousing 152 of slider assembly 150, body 161 of torsion spring 160, andupper leg 162 of torsion spring 160, to drive plate 142 to urge driveplate 142 in a proximal direction, while a second, opposite force actson drive plate 142 and, thus, upper leg 162 of torsion spring 160 in adistal direction to control the amount of compression of tissue betweenjaw members 110, 120. Once the second, opposite force exceeds the springforce of torsion spring 160, proximal movement of proximal housing 152no longer results in proximal movement of drive plate 142 but, rather,results in further tensioning of torsion spring 160, wherein torsionspring 160 is wound-up, absorbing the force imparted thereto frommovement of movable handle 40. Thus, once this point has been reached,further proximal translation of proximal housing 152 of slider assembly150 urges body 161 of torsion spring 160 proximally while upper leg 162of torsion spring 160 remains in position as a result of the wind-uptensioning of torsion spring 160. With upper leg 162 of torsion spring160 retained in position, drive plate 142 is likewise retained inposition despite the proximal translation of movable handle 40. As such,an upper threshold of pressure applied to tissue grasped between jawmembers 110, 120 is defined.

Referring to FIG. 27, upon achieving the activation position of movablehandle 40, button activation post 196 (FIG. 1) of movable handle 40contacts depressible button 192 sufficiently so as to depressdepressible button 192 into fixed handle portion 28 of housing 20 toactivate switch 194. Switch 194, as noted above, is disposed inelectrical communication with the generator (not shown) andelectrically-conductive plates 132 of jaw members 110, 120 (FIG. 14),such that activation of switch 194 initiates the supply of energy toelectrically-conductive plates 132 (FIG. 14) to treat, e.g., coagulate,cauterize, and/or seal, tissue grasped therebetween.

Referring to FIGS. 28-30, once tissue has been treated or where it isonly desired to cut tissue, knife blade 174 may be advanced between jawmembers 110, 120 to cut tissue grasped therebetween. In order to advanceknife blade 174 from the retracted position to the extended position,trigger 72 is pulled proximally against the bias of biasing member 71from the un-actuated position to the actuated position. As trigger 72 ispulled proximally, linkage 76 is urged to pivot counter-clockwise (fromthe orientation illustrated in FIG. 28) such that upper end slot 77 b oflinkage 76 is moved distally. Distal movement of upper end slot 77 burges tube 78 to translate distally and, in turn, urges knife plate 172to translate distally. This movement is permitted as, with movablehandle 40 in or near the compressed or actuated position, proximalhousing 152 is displaced relative to the movement path of lockout peg79.

As detailed above, movement of trigger 72 from the un-actuated positionto the actuated position urges knife plate 172 distally. Morespecifically, knife plate 172 is urged distally such that knife blade174 is advanced distally from the retracted position to the extendedposition. As knife blade 174 is advanced distally, knife blade 174extends through knife slots 132 b defined within electrically-conductiveplates 132 of jaw members 110, 120 defined by the respective knife slots112 b, 122 b of electrically-conductive plates 112, 122 to cut tissuegrasped between jaw members 110, 120.

Upon release, trigger 72 and knife plate 172 are returned proximallyunder the bias of biasing member 71 such that knife blade 174 isreturned to the retracted position. Thereafter, movable handle 40 may bereleased, allowing movable handle 40 to return to the initial positionunder the bias of lower leg 163 of torsion spring 160 abutting block 26of housing 20, thereby returning jaw members 110, 120 to thespaced-apart position and releasing the treated and/or divided tissue.

Referring generally to FIGS. 1-10, the assembly of surgical instrument10 is detailed. Unless necessitated by the positioning of thecomponents, e.g., wherein a second component obstructs a firstcomponents, the assembly of surgical instrument 10 need not be performedin the order detailed below. Further, it is contemplated that certainassemblies and/or components, e.g., each of the jaw members 110, 120(the assembly of which is detailed above), be pre-assembled prior toengagement with the other components of surgical instrument 10.

The previously-assembled jaw members 110, 120 are manipulated such thatthe proximal flanges 134 a of jaw member 110 receive the proximalflanges 134 a of jaw member 120 therebetween with the pivot apertures134 c thereof aligned with one another. Leads 107, which extendproximally from jaw members 110, 120, are routed proximally throughshaft 80.

Knife plate 172 (including knife blade 174 at the distal end thereof) isslidably coupled to drive plate 142 via insertion of knife blade 174between plate 142 and knife guide 148 with the longitudinal edges ofknife plate 172 are slidably received within track edges 146 of driveplate 142. Prior to or after coupling of knife plate 172 and drive plate142, coupling tube 78 is snap-fit about legs 173 of knife plate 172.

With knife plate 172 and drive plate 142 coupled to one another, thepair is inserted through the proximal end of shaft 80 until cam pinaperture 147 of drive plate 142 and elongated opening 176 of knife blade174 are aligned with cam slots 134 d of jaw members 110, 120. Once thisalignment has been achieved, cam pin 105 may be inserted therethrough tooperably couple drive plate 142 with jaw members 110, 120.

With cam pin 105 operably coupling jaw members 110, 120 with drive plate142, proximal flanges 134 a of jaw members 110, 120 are inserted betweenclevis members 84 of shaft 80 such that pivot pin apertures 86 of shaft80 are aligned with pivot apertures 134 c of jaw members 110, 120. Withapertures 134 c and 86 aligned with one another, pivot pin 103 may beinserted therethrough to pivotably couple jaw members 110, 120 to shaft80 and one another. Achieving the above insertion of cam pin 105 and/orpivot pin 103 may be facilitated using appropriate fixturing (not shown)and/or a lead pin (not shown). To secure pivot pin 103 in position,pivot pin 103 may be laser welded to the exterior of shaft 80 about theperimeter of pivot pin 103 and apertures 86 of shaft 80. Testing may beperformed after welding to ensure proper pivoting of jaw members 110,120 in response to translation of drive plate 142 and to ensure properadvancement and retraction of knife blade 174 relative to jaw members110, 120.

In order to assemble and install drive assembly 140, torsion spring 160is positioned within proximal housing 152 of slider assembly 150 suchthat post 153 of proximal housing 152 receives body 161 of torsionspring 160 with upper and lower legs 162, 163, respectively, of torsionspring 160 extending from proximal housing 152. Proximal housing 152and/or the proximal end of drive plate 142 are then manipulated suchthat the proximal end of drive plate 142 is slidably supported atopproximal housing 152 with upper leg 162 of torsion spring 160 extendingthrough slot 144 defined within drive plate 142.

The assembly thus far (end effector assembly 100, shaft 80, drive plate142, slider assembly 150, and knife assembly 170) is positioned withinone of the first or second housing components of housing 20 such thatshaft 80 is fixed in position relative thereto, proximal housing 152 isslidably received within longitudinal track 24 of housing 20, and lowerleg 163 of torsion spring 160 abuts a distally-facing surface of block26 of housing 20. Leads 107 are routed around housing 20 so as not tointerfere with the internal operating components thereof, are connectedto activation assembly 190, and are connected to electrosurgical cable200, which extends from housing 20.

Next, pivot pin 48 for movable handle 40 is inserted into the pivotaperture 23 of the housing component of housing 20 and, thereafter,movable handle 40 is positioned to pivotably couple to housing 20 viapivot pin 48 and such that engagement bulge 51 is operably coupled withmandrel 158 of slider assembly 150, with drive plate 142 and knife plate172 received within cut-out 49 of movable handle 40. Trigger 72 is thenpositioned atop and at least partially about movable handle 40, withpivot pin 48 pivotably coupling trigger 72 to housing 20. Biasing spring71 is also connected for biasing trigger 72 towards the un-actuatedposition. Linkage 76 is then disposed atop trigger 72 such that peg 77 dis pivotably engaged with pivot boss 25 of the housing component ofhousing 20, coupling tube 78 is received within upper end cam slot 77 bof linkage 76, and lower end cam slot 77 c of linkage 76 receives post75 c of trigger 72. Thus, trigger and linkage 76 are operably coupled tohousing 20, knife plate 172, and one another.

Once the internal components within housing 20 are assembled and inplace, as detailed above, the outer housing components of housing 20 arepositioned such that the outer housing components cooperate to enclosethe internal components. The outer housing components may be engagedwith one another in any suitable fashion, e.g., screws, snap-fitengagements, ultrasonic welding, adhesion, etc.

Finally, testing is performed to ensure that surgical instrument 10 isworking properly. Such testing may include jaw force testing; testingusing a gauge pin (not shown) to test the maximum jaw aperture betweenjaw members 110, 120 at the distal tips thereof; cut testing of theknife blade 174 using cut test media (not shown); testing of the gapdistance between the tissue-contacting surfaces 132 a of jaw members110, 120 (as set by the one or more stop members 132 e) in theapproximated position thereof at various positions along the lengths ofjaw members 110, 120; and/or performing electrical continuity testing.

The various embodiments disclosed herein may also be configured to workwith robotic surgical systems and what is commonly referred to as“Telesurgery.” Such systems employ various robotic elements to assistthe surgeon and allow remote operation (or partial remote operation) ofsurgical instrumentation. Various robotic arms, gears, cams, pulleys,electric and mechanical motors, etc. may be employed for this purposeand may be designed with a robotic surgical system to assist the surgeonduring the course of an operation or treatment. Such robotic systems mayinclude remotely steerable systems, automatically flexible surgicalsystems, remotely flexible surgical systems, remotely articulatingsurgical systems, wireless surgical systems, modular or selectivelyconfigurable remotely operated surgical systems, etc.

The robotic surgical systems may be employed with one or more consolesthat are next to the operating theater or located in a remote location.In this instance, one team of surgeons or nurses may prep the patientfor surgery and configure the robotic surgical system with one or moreof the instruments disclosed herein while another surgeon (or group ofsurgeons) remotely control the instruments via the robotic surgicalsystem. As can be appreciated, a highly skilled surgeon may performmultiple operations in multiple locations without leaving his/her remoteconsole which can be both economically advantageous and a benefit to thepatient or a series of patients.

The robotic arms of the surgical system are typically coupled to a pairof master handles by a controller. The handles can be moved by thesurgeon to produce a corresponding movement of the working ends of anytype of surgical instrument (e.g., end effectors, graspers, knifes,scissors, etc.) which may complement the use of one or more of theembodiments described herein. The movement of the master handles may bescaled so that the working ends have a corresponding movement that isdifferent, smaller or larger, than the movement performed by theoperating hands of the surgeon. The scale factor or gearing ratio may beadjustable so that the operator can control the resolution of theworking ends of the surgical instrument(s).

The master handles may include various sensors to provide feedback tothe surgeon relating to various tissue parameters or conditions, e.g.,tissue resistance due to manipulation, cutting or otherwise treating,pressure by the instrument onto the tissue, tissue temperature, tissueimpedance, etc. As can be appreciated, such sensors provide the surgeonwith enhanced tactile feedback simulating actual operating conditions.The master handles may also include a variety of different actuators fordelicate tissue manipulation or treatment further enhancing thesurgeon's ability to mimic actual operating conditions.

From the foregoing and with reference to the various figure drawings,those skilled in the art will appreciate that certain modifications canalso be made to the present disclosure without departing from the scopeof the same. While several embodiments of the disclosure have been shownin the drawings, it is not intended that the disclosure be limitedthereto, as it is intended that the disclosure be as broad in scope asthe art will allow and that the specification be read likewise.Therefore, the above description should not be construed as limiting,but merely as exemplifications of particular embodiments. Those skilledin the art will envision other modifications within the scope and spiritof the claims appended hereto.

What is claimed is:
 1. A jaw member configured for use with a surgicalinstrument, comprising: an electrically-conductive plate defining aplanar tissue-contacting surface and a pair of legs extending from theplanar tissue-contacting surface, the legs defining outwardly-facingsurfaces and inwardly-facing surfaces; a spacer including a bodypositioned towards a proximal portion of the electrically-conductiveplate, and a pair of arms extending distally from the body adjacent theinwardly-facing surfaces to provide structural support to theelectrically-conductive plate; a jaw frame including a distal jawsupport disposed within the body of the spacer, the jaw frame supportingthe spacer and the electrically-conductive plate; and an outer housingdisposed about at least a portion of the outwardly-facing surfaces ofthe legs of the electrically-conductive plate, the spacer, and the jawframe, an outer surface of the outer housing is flush with an outersurface of the distal jaw support.
 2. The jaw member according to claim1, wherein the spacer further includes a pair of wings extendingoutwardly from the body, the wings configured to receive free ends ofthe legs of the electrically-conductive plate to engage the spacer withthe electrically-conductive plate.
 3. The jaw member according to claim1, wherein the legs of the electrically-conductive plate each define aplurality of apertures therethrough.
 4. The jaw member according toclaim 3, wherein the arms of the spacer define protrusions extendingoutwardly therefrom, each protrusion extending at least partiallythrough one of the plurality of apertures.
 5. The jaw member accordingto claim 4, wherein a portion of the outer housing extends at leastpartially through one of the plurality of apertures of each of the legsof the electrically-conductive plate.
 6. The jaw member according toclaim 1, wherein the spacer further defines a tunnel configured toreceive a wire for connecting the electrically-conductive plate to asource of energy.
 7. The jaw member according to claim 1, wherein thedistal jaw support of the jaw frame extends from about 50% to about 75%of the length of the electrically-conductive plate.
 8. The jaw memberaccording to claim 7, wherein the jaw frame includes a proximal flangeportion extending proximally from the distal jaw support, the proximalflange portion defining at least one pivot aperture and at least one camslot.
 9. The jaw member according to claim 1, wherein the legs extendperpendicularly from the planar tissue-contacting surface.